Modular shank assembly for an earth-boring tool, earth-boring tools including modular shanks assemblies, and related methods

ABSTRACT

A shank assembly includes a neck portion, a shank portion defining a cylindrical aperture extending therethrough, and an anchor tube secured to the neck portion and extending through the shank portion, the anchor tube and the shank portion defining an annular cavity therebetween, and an electronics module disposed within the annular cavity. The annular cavity is formed to maximize space for electronics while maintaining structural integrity of a crown and shank of an earth-boring tool. A method includes disposing the anchor tube of a shank assembly through the cylindrical aperture and securing the anchor tube to a neck portion of the shank assembly, disposing the electronics module within the annular cavity, and disposing the shank portion and anchor tube of the shank assembly at least partially within a crown of the earth-boring tool such that annular cavity extends into the crown in an axial direction a distance that is between about 10% and about 80% of an overall axial length of the crown.

TECHNICAL FIELD

This disclosure relates generally to modular shank assemblies forearth-boring tools for use in drilling wellbores. The disclosure furtherrelates to methods of forming modular shank assemblies.

BACKGROUND

Oil wells (wellbores) are usually drilled with a drill string. The drillstring includes a tubular member having a drilling assembly thatincludes a drill bit at its bottom end. The drilling assembly may alsoinclude devices and sensors that provide information relating to avariety of parameters relating to the drilling operations (“drillingparameters”), behavior of the drilling assembly (“drilling assemblyparameters”) and parameters relating to the formations penetrated by thewellbore (“formation parameters”). A drill bit and/or reamer attached tothe bottom end of the drilling assembly is rotated by rotating the drillstring from the drilling rig and/or by a drilling motor (also referredto as a “mud motor”) in the bottom hole assembly (“BHA”) to removeformation material to drill the wellbore.

BRIEF SUMMARY

One or more embodiments of the present disclosure include a shankassembly. The shank assembly may include a neck portion, a shank portionextending from the neck portion and defining a cylindrical apertureextending longitudinally therethrough, one or more sealing ringsdisposed at an interface between the neck portion and the shank portion,an anchor tube secured to the neck portion and extending through theshank portion, the anchor tube and the shank portion defining an annularcavity therebetween, and an electronics module disposed within theannular cavity and including at least one of an accelerometer, amagnetometer, and a temperature sensor.

Some embodiments of the present disclosure include an earth-boring tool.The earth-boring tool may include a shank assembly and a crown securedto the shank assembly. The shank assembly may include a neck portion, ashank portion extending from the neck portion and defining a cylindricalaperture extending longitudinally therethrough, an anchor tube securedto the neck portion and extending through the shank portion, the anchortube and the shank portion defining an annular cavity therebetween, andan electronics module disposed within the annular cavity configured tomeasure one or more of an annular pressure, a bore pressure,weight-on-bit, torque-on-bit, or a temperature. The crown may be securedto the shank portion and the anchor portion, wherein the annular cavityextends into the crown in an axial direction a distance that is betweenabout 10% and about 80% of an overall axial length of the crown.

Further embodiments of the present disclosure include a method offorming an earth-boring tool. The method may include disposing an anchortube of a shank assembly through a cylindrical aperture of a shankportion of the shank assembly and securing the anchor tube to a neckportion of the shank assembly, disposing an electronics module within anannular cavity defined between an inner surface of the shank portion andan outer surface the anchor tube of the shank assembly, and disposingthe shank portion and anchor tube of the shank assembly at leastpartially within a crown of the earth-boring tool such that annularcavity extends into the crown in an axial direction a distance that isbetween about 10% and about 80% of an overall axial length of the crown.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed understanding of the present disclosure, reference shouldbe made to the following detailed description, taken in conjunction withthe accompanying drawings, in which like elements have generally beendesignated with like numerals, and wherein:

FIG. 1 is a schematic diagram of a wellbore system comprising a drillstring that includes one or more sensors according to an embodiment ofthe present disclosure;

FIG. 2 is a perspective view of a drill bit according to an embodimentof the present disclosure;

FIG. 3A is a perspective view of a shank of a drill bit having anend-cap disposed at least partially therein according to an embodimentof the present disclosure;

FIG. 3B is a cross-sectional view of a shank and an end-cap according toanother embodiment of the present disclosure;

FIG. 3C is a perspective view of two end-caps disposed adjacent to oneanother according to one or more embodiments of the present disclosure;

FIG. 4A is a perspective view of a shank assembly according to one ormore embodiments of the present disclosure;

FIG. 4B is a partial perspective view of the shank assembly of FIG. 4B;

FIG. 5 is a cross-sectional view of an earth-boring tool including ashank assembly according to one or more embodiments of the presentdisclosure; and

FIG. 6 is a perspective view of a shank assembly according to one ormore embodiments of the present disclosure.

DETAILED DESCRIPTION

The illustrations presented herein are not actual views of anyparticular drilling system, drilling tool assembly, or component of suchan assembly, but are merely idealized representations, which areemployed to describe the present invention.

As used herein, the terms “bit” and “earth-boring tool” each mean andinclude earth-boring tools for forming, enlarging, or forming andenlarging a wellbore. Non-limiting examples of bits include fixed-cutter(“drag”) bits, fixed-cutter coring bits, fixed-cutter eccentric bits,fixed-cutter bicenter bits, fixed-cutter reamers, expandable reamerswith blades bearing fixed cutters, and hybrid bits including both fixedcutters and movable cutting structures (roller cones).

As used herein, any relational term, such as “first,” “second,” “lower,”“upper,” “outer,” “inner,” etc., is used for clarity and convenience inunderstanding the disclosure and accompanying drawings, and does notconnote or depend on any specific preference or order, except where thecontext clearly indicates otherwise.

As used herein, the terms “comprising,” “including,” “containing,”“characterized by,” and grammatical equivalents thereof are inclusive oropen-ended terms that do not exclude additional, un-recited elements ormethod steps, but also include the more restrictive terms “consistingof,” “consisting essentially of,” and grammatical equivalents thereof.

As used herein, the term “may” with respect to a material, structure,feature, or method act indicates that such is contemplated for use inimplementation of an embodiment of the disclosure, and such term is usedin preference to the more restrictive term “is” so as to avoid anyimplication that other compatible materials, structures, features, andmethods usable in combination therewith should or must be excluded.

As used herein, the term “configured” refers to a size, shape, materialcomposition, and arrangement of one or more of at least one structureand at least one apparatus facilitating operation of one or more of thestructure and the apparatus in a predetermined way.

As used herein, the singular forms following “a,” “an,” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items.

As used herein, the term “substantially” in reference to a givenparameter, property, or condition means and includes to a degree thatone skilled in the art would understand that the given parameter,property, or condition is met with a small degree of variance, such aswithin acceptable manufacturing tolerances. For example, a parameterthat is substantially met may be at least about 90% met, at least about95% met, or even at least about 99% met.

As used herein, the term “about” used in reference to a given parameteris inclusive of the stated value and has the meaning dictated by thecontext (e.g., it includes the degree of error associated withmeasurement of the given parameter).

FIG. 1 is a schematic diagram of an example of a drilling system 100that may utilize the apparatuses and methods disclosed herein fordrilling wellbores. FIG. 1 shows a wellbore 102 that includes an uppersection 104 with a casing 106 installed therein and a lower section 108that is being drilled with a drill string 110. The drill string 110 mayinclude a tubular member 112 that carries a drilling assembly 114 at itsbottom end. The tubular member 112 may be made up by joining drill pipesections or it may be a string of coiled tubing. A drill bit 116 may beattached to the bottom end of the drilling assembly 114 for drilling thewellbore 102 of a selected diameter in a formation 118.

The drill string 110 may extend to a rig 120 at the surface 122. The rig120 shown is a land rig 120 for ease of explanation. However, theapparatuses and methods disclosed equally apply when an offshore rig 120is used for drilling wellbores under water. A rotary table 124 or a topdrive may be coupled to the drill string 110 and may be utilized torotate the drill string 110 and to rotate the drilling assembly 114, andthus the drill bit 116 to drill the wellbore 102. A drilling motor 126(also referred to as “mud motor”) may be provided in the drillingassembly 114 to rotate the drill bit 116. The drilling motor 126 may beused alone to rotate the drill bit 116 or to superimpose the rotation ofthe drill bit 116 by the drill string 110. The rig 120 may also includeconventional equipment, such as a mechanism to add additional sectionsto the tubular member 112 as the wellbore 102 is drilled. A surfacecontrol unit 128, which may be a computer-based unit, may be placed atthe surface 122 for receiving and processing downhole data transmittedby sensors 140 in the drill bit 116 and sensors 140 in the drillingassembly 114, and for controlling selected operations of the variousdevices and sensors 140 in the drilling assembly 114. The sensors 140may include one or more of sensors 140 that determine acceleration,weight on bit, torque, pressure, cutting element positions, rate ofpenetration, inclination, azimuth formation/lithology, etc. In someembodiments, the surface control unit 128 may include a processor 130and a data storage device 132 (or a computer-readable medium) forstoring data, algorithms, and computer programs 134. The data storagedevice 132 may be any suitable device, including, but not limited to, aread-only memory (ROM), a random-access memory (RAM), a Flash memory, amagnetic tape, a hard disk, and an optical disc. During drilling, adrilling fluid from a source 136 thereof may be pumped under pressurethrough the tubular member 112, which discharges at the bottom of thedrill bit 116 and returns to the surface 122 via an annular space (alsoreferred as the “annulus”) between the drill string 110 and an insidewall 138 of the wellbore 102.

The drilling assembly 114 may further include one or more downholesensors 140 (collectively designated by numeral 140. The sensors 140 mayinclude any number and type of sensors 140, including, but not limitedto, sensors 140 generally known as the measurement-while-drilling (MWD)sensors 140 or the logging-while-drilling (LWD) sensors 140, and sensors140 that provide information relating to the behavior of the drillingassembly 114, such as drill bit rotation (revolutions per minute or“RPM”), tool face, pressure, vibration, whirl, bending, and stick-slip.The drilling assembly 114 may further include a controller unit 142 thatcontrols the operation of one or more devices and sensors 140 in thedrilling assembly 114. For example, the controller unit 142 may bedisposed within the drill bit 116 (e.g., within a shank and/or crown ofa bit body of the drill bit 116). The controller unit 142 may include,among other things, circuits to process the signals from sensor 140, aprocessor 144 (such as a microprocessor) to process the digitizedsignals, a data storage device 146 (such as a solid-state-memory), and acomputer program 148. The processor 144 may process the digitizedsignals, and control downhole devices and sensors 140, and communicatedata information with the surface control unit 128 via a two-waytelemetry unit 150.

The drill bit 116 may include a face section 152 (or bottom section).The face section 152 or a portion thereof may face the undrilledformation 118 in front of the drill bit 116 at the wellbore 102 bottomduring drilling. In some embodiments, the drill bit 116 may include oneor more cutting elements and, more specifically, a blade projecting fromthe face section 152.

FIG. 2 is perspective view of an earth-boring tool 200 according to anembodiment of the present disclosure. The earth-boring tool 200 maycomprise a body 202 including a neck 206, a shank 208, and a crown 210.In some embodiments, the bulk of the body 202 may be constructed ofsteel, or of a ceramic-metal composite material including particles ofhard material (e.g., tungsten carbide) cemented within a metal matrixmaterial. The body 202 of the earth-boring tool 200 may have an axialcenter defining a center longitudinal axis 205 that may generallycoincide with a rotational axis of the earth-boring tool 200. The centerlongitudinal axis 205 of the body 202 may extend in a directionhereinafter referred to as an “axial direction.”

The body 202 may be connectable to a drill string 110 (FIG. 1). Forexample, the neck 206 of the body 202 may have a tapered upper endhaving threads thereon for connecting the earth-boring tool 200 to a boxend of a drilling assembly 114 (FIG. 1). The shank 208 may include alower straight section that is fixedly connected to the crown 210 at ajoint. In some embodiments, the crown 210 may include a plurality ofblades 214.

The plurality of blades 214 may also extend from the end of the body 202opposite the neck 206 and may extend in both the axial and radialdirections. Each blade 214 may have multiple profile regions as known inthe art (cone, nose, shoulder, and gage). Each blade 214 of theplurality of blades 214 of the earth-boring tool 200 may include aplurality of cutting elements 230 fixed thereto. The plurality ofcutting elements 230 of each blade 214 may be located in a row along aprofile of the blade 214 proximate a rotationally leading face 232 ofthe blade 214.

Fluid courses 234 may be formed between adjacent blades 214 of theplurality of blades 214 and may be provided with drilling fluid by ports218 located at the end of passages leading from an internal fluid plenumextending through the body 202 from a tubular shank 208 at the upper endof the earth-boring tool 200. Nozzles 220 may be secured within theports for enhancing direction of fluid flow and controlling flow rate ofthe drilling fluid. The fluid courses 234 extend to junk slots extendingaxially along the longitudinal side of earth-boring tool 200 betweenblades 214 of the plurality of blades 214.

FIG. 3A is a perspective view of a neck portion 310 of a shank forsecuring to a drill bit 200 (FIG. 2), an end-cap 370 received within theneck portion 310, and an electronics module 390 (e.g., a firstelectronics module). FIG. 3B is a side cross-sectional view of theend-cap 370 at least partially disposed within the neck portion 310.Referring to FIGS. 3A and 3B together, the neck portion 310 of the shankmay include a central bore 380 formed along a center longitudinal axisof the neck portion 310. As is discussed in greater detail below, thecentral bore 380 may be sized and shaped to receive at least a portionof the end-cap 370.

The end-cap 370 may include a first flange 371 at a first longitudinalend (e.g., a lower end) of the end-cap 370, a second flange 373 at asecond opposite longitudinal end (e.g., an upper end) of the end-cap370, and a body portion 375 extending between the first flange 371 andthe second flange 373. The first flange 371 may include a first sealingring 372, and the second flange 373 may include a second sealing ring374. In some embodiments, the end-cap 370 may further include a cap bore376 extending longitudinally (i.e., along a center longitudinal axis)therethrough. As a result, drilling mud may flow through the end-cap370, through the central bore 380 of the neck portion 310 of the shankto the other side of the neck portion 310, and then into the body 202 ofdrill bit 200. Accordingly, the cap bore 376 may be subjected toconditions (e.g., high temperatures and pressures) experienced downhole.

In one or more embodiments, when the end-cap 370 is at least partiallydisposed within the central bore 380, an interior wall 381 of thecentral bore 380 and the end-cap 370 may define an at leastsubstantially annular chamber 360. Furthermore, the annular chamber 360may have a sufficient width to receive (e.g., have disposed therein) theelectronics module 390. Furthermore, the central bore 380 may have asufficiently small diameter as to not detrimentally affect thestructural integrity of the neck portion 310 of the shank. As a result,the electronics module 390 may be disposed within the central bore 380and about the end-cap 370.

The first and second flanges 371, 373 may be sized and shaped to formfluid tight seals with an interior wall 381 of the central bore 380 ofthe neck portion 310 of the shank. In some instances, the first sealingring 372 and the second sealing ring 374 may form a protective,fluid-tight seal between the end-cap 370 and the interior wall 381 ofthe central bore 380 to protect the electronics module 390 from adverseenvironmental conditions (e.g., high pressures and fluids). Theprotective seal formed by the first sealing ring 372 and the secondsealing ring 374 may also be configured to maintain the annular chamber360 at approximately atmospheric pressure.

In one or more embodiments, the first sealing ring 372 and the secondsealing ring 374 are formed of material suitable for a high-pressure,high-temperature environment, such as, for example, a HydrogenatedNitrile Butadiene Rubber (HNBR) O-ring in combination with a PEEKback-up ring. In addition, the end-cap 370 may be secured to the neckportion 310 of the shank with a number of connection mechanisms such as,for example, a secure press-fit using sealing rings 372 and 374, athreaded connection, an epoxy connection, a shape-memory retainer, awelded connection, and/or a brazed connection. It will be recognized bythose of ordinary skill in the art that the end-cap 370 may be held inplace relatively firmly by a relatively simple connection mechanism dueto differential pressure and downward mud flow during drillingoperations.

In some embodiments, at least two end caps 370 a, 370 b may be utilized(e.g., to cross threaded connect) within central bore 380 of the neckportion 310, as depicted in FIG. 3C. Furthermore, in one or moreembodiments, the two end caps 370 may be oriented with the secondflanges 371 of the two end caps 370 facing each other. Additionally, theat least two end caps 370 may include any of the end caps described in,for example, U.S. application Ser. No. 15/888,904, filed Feb. 5, 2018,to Yao et al., the disclosure of which is incorporated in its entiretyby reference herein. Additionally, in one or more embodiments, asdescribed in further detail below, one or more of the at least two endcaps 370 may be integral with one or more elements of the shank (e.g.,an anchor tube (FIG. 4A)).

The electronics module 390 may include a flex-circuit board. Theflex-circuit board may include a high-strength reinforced backbone (notshown) to provide acceptable transmissibility of acceleration effects tosensors such as accelerometers. In addition, other areas of theflex-circuit board bearing non-sensor electronic components may beattached to the end-cap 370 in a manner suitable for at least partiallyattenuating the acceleration effects experienced by the drill bit 200during drilling operations using a material such as a visco-elasticadhesive. In view of the foregoing, the drill bit 200 (FIG. 2) mayinclude any of the shanks, necks, and electronics modules described in,for example, U.S. Pat. No. 8,100,196, to Pastusek et al., filed Feb. 6,2009, issued Jun. 24, 2012, U.S. Pat. No. 7,849,934, to Pastusek et al.,filed Feb. 16, 2007, and U.S. Pat. No. 7,604,072, to Pastusek et al.,filed Jun. 7, 2005, issued Oct. 20, 2009, the disclosures of which areincorporated in their entireties by this reference herein.

The electronics module 390 may be utilized to perform a variety offunctions. In some embodiments, the electronics module 390 may include adata analysis module, which may sample data in different sampling modes,sample data at different sampling frequencies, and analyze data.Furthermore, in one or more embodiments, the electronics module 390 mayinclude a power supply, a processor, a memory, and at least one sensorfor measuring a plurality of physical parameters related to a drillingstate, which may include drill bit conditions, drilling operationconditions, and environmental conditions proximate the drill bit 200(FIG. 2). For example, the sensor may include one or moreaccelerometers, one or more magnetometers, and at least one temperaturesensor.

FIG. 4A is a perspective view of a shank assembly 400 of an earth-boringtool 401 in an exploded configuration according to one or moreembodiments of the present disclosure. FIG. 4B is a partial perspectiveview of the shank assembly 400 of FIG. 4A. FIG. 5 is a cross-sectionalview of the shank assembly 400 of an earth-boring tool 401 in anassembled configuration. Referring to FIGS. 4A-5 together, the shankassembly 400 may include a neck portion 402, a shank portion 404, and ananchor tube 406. In some embodiments, the shank assembly 400 may bemodular. In other words, the shank assembly 400 may be formed ofmultiple distinct parts (e.g., pieces). The shank portion 404 may extendfrom the neck portion 402 opposite an end of the neck portion 402 forconnecting to a drill string. Moreover, the anchor tube 406 may extendthrough the shank portion 404 and may connect to the neck portion 402 ofthe shank assembly 400.

The neck portion 402 may include any of the neck portions describedabove in regard to FIGS. 3A and 3B, and any of the above-described endcaps 370 and electronics module 390 may be disposed within a borehole ofthe neck portion 402. For instance, two end caps may be disposed withinthe neck portion 402, and the two end caps may be oriented with thesecond flanges of the two end caps facing each other, as depicted inFIG. 3C. In additional embodiments, the neck portion 402 may include asingle end cap 370 disposed therein. Moreover, as noted above, the endcap 370 may be integral with or attachable to the anchor tube 406, asdepicted in FIGS. 4A, 4B, and 5.

In one or more embodiments, the shank portion 404 may include a hollowcylinder defining a cylindrical aperture 408 extending along alongitudinal axis 409 of the shank assembly 400. The shank portion 404may be at least substantially centered about the longitudinal axis 409of the shank assembly 400. In some embodiments, the shank portion 404may be integral with the neck portion 402. For instance, the shankportion 404 and the neck portion 402 of the shank assembly 400 may forman integral member (e.g., part or piece). As a non-limiting example, theshank portion 404 and the neck portion 402 may form a bell shapedmember.

As noted above, in some embodiments, the anchor tube 406 may extendthrough the shank portion 404 and through the cylindrical aperture 408of the shank portion 404. Together, the shank portion 404 and the anchortube 406 may define an annular cavity 410 between an inner surface ofthe shank portion 404 and an outer surface of the anchor tube 406. Awidth of the annular cavity 410 (i.e., a distance between an innerdiameter and an outer diameter of the annular cavity 410) may be betweenabout 10% and about 70% of an overall radius of the shank portion 404.In some embodiments, the width of the annular cavity 410 may be betweenabout 30% and about 50% of the overall radius of the shank portion 404.For instance, the width of the annular cavity 410 may be 40% of theoverall radius of the shank portion 404.

In some embodiments, the annular cavity 410 defined by the shank portion404 and the anchor tube 406 may be sized and shaped to receive anelectronics module 412 (e.g., a second electronics module 412). In someembodiments, the electronics modules 412 may include a flexible printedcircuit board (“PCB”) mounted to circular (e.g., annular) frame. Theframe may include a high-strength reinforced backbone to provideacceptable transmissibility of acceleration effects to sensors such asaccelerometers. In addition, other areas of the electronics module 412bearing non-sensor electronic components may be attached to the innersurface of the shank portion 404 and/or the outer surface of the anchortube 406 in a manner suitable for at least partially attenuating theacceleration effects experienced by the drill bit 200 (FIG. 2) duringdrilling operations using a material such as a visco-elastic adhesive.As non-limited example, the electronics module 412 may include any ofthe electronics modules described in, for example, U.S. Pat. No.8,100,196, to Pastusek et al., filed Feb. 6, 2009, issued Jun. 24, 2012,U.S. Pat. No. 7,849,934, to Pastusek et al., filed Feb. 16, 2007, andU.S. Pat. No. 7,604,072, to Pastusek et al., filed Jun. 7, 2005, issuedOct. 20, 2009, the disclosures of which are incorporated in theirentireties by this reference herein.

The electronics module 412 may be utilized to perform a variety offunctions. In some embodiments, the electronics module 412 may include adata analysis module, which may sample data in different sampling modes,sample data at different sampling frequencies, and analyze data.Furthermore, in one or more embodiments, the electronics module 412 mayinclude a power supply, a processor, a memory, and at least one sensorfor measuring a plurality of physical parameters related to a drillingstate, which may include drill bit conditions, drilling operationconditions, and environmental conditions proximate the drill bit 200(FIG. 2). For example, the sensor may include one or moreaccelerometers, one or more magnetometers, and at least one temperaturesensor. Additionally, the electronics module 412 may include sensors formeasuring and determining one or more of weight-on-bit (WOB),torque-on-bit (TOB), and bore and annular pressures.

In some embodiments, the electronics module 412 may further include oneor more strain gauges secured to the inner surface of the shank portion404 and/or the outer surface of the anchor tube 406. For example, theelectronics module 412 may include a piezoelectric gauge. For instance,the electronics module 412 may include a sensor that utilizes apiezoelectric effect (as is known in the art) to measure changes inpressure, acceleration, temperature, strain, and/or force by convertingthem into an electric charge. In such embodiments, the one or morestrain gauges may be secured to the inner surface of the shank portion404 and/or the outer surface of the anchor tube 406 via one or more ofadhesives, welds, cements, etc. As another non-limiting example, the oneor more strain gauges may be secured to the inner surface of the shankportion 404 and/or the outer surface of the anchor tube 406 via anepoxy. In other embodiments, the one or more strain gauges may besecured to the inner surface of the shank portion 404 and/or the outersurface of the anchor tube 406 via one or more tack welds or ceramiccements.

Furthermore, in one or more embodiments, the shank portion 404 mayinclude one or more integrated sensors 430 within or on a wall of theshank portion 404. For example, the shank portion 404 may include one ormore integrated sensors 430 for measuring WOB, TOB, and bore and annularpressure. For instance, the shank portion 404 may include any of thesensors and sensor assemblies described in U.S. application Ser. No.15/888,904, filed Feb. 5, 2018, to Yao et al., the disclosure of whichis incorporated in its entirety by reference herein.

In one or more embodiments, the annular cavity 410, in which theelectronics module 412 is disposed, may not be subject to the highpressures and/or other environmental conditions experienced downhole.However, an interior of the anchor tube 406 and an exterior of the shankportion 404 may be subjected to the high pressures, temperatures andother environmental conditions experienced downhole during a drillingoperation. Furthermore, in some embodiments, the shank portion 404and/or the anchor tube 406 may flex (e.g., bow outward or outward,bulge, etc.) due to the disparity between the high pressure within theanchor tube 406 and/or exterior to the shank portion 404 and theatmospheric pressure within the annular cavity 410. Moreover, due to theflexing of the shank portion 404 and/or the anchor tube 406, straingauges of the electronics module 412 may be used to measure a strainexhibited by the shank portion 404 and/or the anchor tube 406, and basedon the measured strain and a known thickness of the shank portion 404and/or the anchor tube 406, the surface control unit 128 (FIG. 1), anexternal controller, and/or an operator can determine one or more of aborehole pressure, an annulus pressure, a pressure drop across the drillbit 200 (FIG. 2) (e.g., a drill bit 200 including multiple sensors atdifferent locations), etc. Furthermore, determining one or more of theborehole pressure and the annulus pressure enables the surface controlunit 128 (FIG. 1) to measure torque on bit (“TOB”) and weight on bit(“WOB”).

As shown in FIG. 5, the shank portion 404 may be connected to a crown414 of the earth-boring tool 401. In some embodiments, the shank portion404 may be at least partially disposed within a receiving aperture ofthe crown 414. In additional embodiments, the crown 414 may be at leastpartially received into a portion of the shank portion 404. In one ormore embodiments, one or more ring seals 417 may be disposed between alongitudinal end of the shank portion 404 opposite the neck portion 402and the crown 414. In some instances, the one or more ring seals 417 mayform a protective, fluid-tight seal between the crown 414 and the shankportion 404 of the shank assembly to protect the electronics module 412from adverse environmental conditions (e.g., high pressures). Theprotective seal formed by the one or more ring seals 417 may also beconfigured to maintain the annular cavity 410 at approximatelyatmospheric pressure. In one or more embodiments, the one or more ringseals 417 are formed of material suitable for a high-pressure,high-temperature environment, such as, for example, an HNBR O-ring incombination with a PEEK back-up ring. In additional embodiments, theshank assembly may or may not include one or more ring seals 417, andthe shank portion 404 may be secured to the crown 414 with a number ofconnection mechanisms such as, for example, a secure press-fit usingring seals 417, a threaded connection, an epoxy connection, ashape-memory retainer, a welded connection, and/or a brazed connection.Additionally, the shank portion 404 and/or the neck portion 402 may haveone or more cable (e.g., wire) pathways extending therethrough forconnection to the electronics module 412 and other sensors (e.g.,sensors integrated with the shank portion 404).

Additionally, in some embodiments, the annular cavity 410 may extendlongitudinally at least partially into the crown 414. For instance, theannular cavity 410 may extend into the crown 414 in an axial direction adistance D that is between about 5% and about 80% of an overall axiallength of the crown 414. As used herein, the term “overall axial length”of the crown 414 may refer to a length extending from an uppermostsurface the crown 414 (e.g., a surface at the interface of the crown 414and the shank portion 404) to a lowermost surface of the nose region ofthe crown 414 in the axial direction. In some embodiments, the distanceD may be between about 30% and about 60% of the overall axial length ofthe crown 414. For example, the distance D may be between about 45% ofthe overall axial length of the crown 414. Additionally, in someembodiments, the distance D may be within a range of about 0.25 inch andabout 5.00 inches. For example, the distance D may be within a range ofabout 1.5 inches and about 3.0 inches. For instance, the distance D maybe about 2.0 inches. In view of the foregoing, in some embodiments, atleast a portion of the electronics module 412 may be disposed withinannular cavity 410 and at least partially within the crown 414 of theearth-boring tool 401.

Referring still to FIGS. 4A-5, the anchor tube 406 may be attached tothe neck portion 402 and the crown 414 of the earth-boring tool 401 andmay be at least substantially centered about the longitudinal axis 409of the shank assembly 400. In some embodiments, the anchor tube 406 maybe threaded on a longitudinal end attached to the neck portion 402 andmay be connected to the neck portion 402 via a threaded connection. Inadditional embodiments, the anchor tube 406 may be connected to the neckportion 402 via one or more of an epoxy connection, a shape-memoryretainer, a welded connection, and/or a brazed connection. Furthermore,the anchor tube 406 may be connected to the neck portion 402 via anycombination of the above-described connections. Additionally, in someembodiments, as described above, the anchor tube 406 may be integralwith the end cap 370, as shown in FIGS. 4A-5. For example, the anchortube 406 and the end cap 370 may form a single integral member. As anon-limiting example, the anchor tube 406 may connected to the end cap370 via a circumferential weld. In further embodiments, the end cap 370and anchor tube 406 may be separate and distinct from each other, asshow in FIG. 6 and described below.

In some embodiments, a longitudinal end 420 of the anchor tube 406opposite the neck portion 402 of the shank assembly 400 may include oneor more annular recesses 422, 424 for receiving one or more sealingrings 426, 428. Furthermore, in some embodiments, the longitudinal end420 of the anchor tube 406 may be secured to the crown 414 via apress-fit using the one or more sealing rings 426, 428. In additionalembodiments, the longitudinal end 420 of the anchor tube 406 may besecured to the crown via one or more of a threaded connection, an epoxyconnection, a shape-memory retainer, a welded connection, and/or abrazed connection.

Additionally, the anchor tube 406 may include a cylindrical aperture 416extending along a longitudinal length of the anchor tube 406. Forinstance, the cylindrical aperture 416 may be defined by an innersurface of the anchor tube 406. In some embodiments, a ratio of adiameter of the cylindrical aperture 416 and an outer diameter of theshank portion 404 may be within a range of about 0.10 and about 0.40. Inone or more embodiments, the cylindrical aperture 416 may define a fluidflow pathway (i.e., an internal fluid plenum) for drilling fluid (e.g.,drilling fluid from the source (FIG. 1)). Furthermore, the fluid flowpathway may be connected to the nozzles 220 (FIG. 2) disposed withinports 218 (FIG. 2) of the crown 414 via internal fluid passagewayswithin the crown 414. Furthermore, the cylindrical aperture 416 may havea sufficient diameter to permit a conventional amount of drilling fluidto flow through anchor tube 406 and through the nozzles 220 during adrilling operation.

In some embodiments, the anchor tube 406 may maintain at leastsubstantially a same diameter throughout a longitudinal length of theanchor tube extending through the shank portion 404 of the shankassembly 400 and into the crown 414 of the earth-boring tool 401.

Additionally, the annular cavity 410 may have a sufficiently small widthto maintain sufficient dimensions of the earth-boring tool 401 along amain load path and shoulder region (FIG. 2) for performing conventionalearth-boring tool operations. In other words, the shank assembly 400described herein may maintain a structural integrity of the earth-boringtool 401. For instance, a ratio of a cross-sectional area of material(e.g., a combination of the material of the shank portion 404 and theanchor tube 406) (referred to hereinafter as the “materialcross-sectional area”) extending through a plane to which thelongitudinal axis of the shank assembly 400 is orthogonal and an overallcross-sectional area defined by the outer diameter of the shank portion404 is within a range of 0.50 and about 0.90. For example, a ratio ofthe material cross-sectional area and the overall cross-sectional areamay be within a range of about 0.60 and about 0.80. As anothernon-limiting example, a ratio of the material cross-sectional area andthe overall cross-sectional area may be about 0.70. Additionally, athickness of the wall of the shank portion 404 (e.g., a radial distancebetween an inner surface and an outer surface of the shank portion 404)may be between about 15% and about 75% of an overall radius of the ofthe shank portion 404 (e.g., a radial distance between the longitudinalaxis 409 of the shank assembly 400 and the outer surface of the shankportion 404). For example, the thickness of the shank portion 404 may bebetween about 25% and about 65% of the overall radius of the shankportion 404. For instance, the thickness of the shank portion 404 may beabout 45% of the overall radius of the shank portion 404.

Referring to FIGS. 3A-5 together, in some embodiments, a ratio of avolume of the annular chamber 360 and a volume the annular cavity 410may be within a range of about 1.25 and about 0.75. In some embodiments,a ratio of the volume of the annular chamber 360 and the volume theannular cavity 410 may be about 1.0.

Additionally, in some embodiments, the shank assembly 400 may haveminimal to no increase in shank length in comparison to conventionalearth-boring tools. As result, the shank assembly 400 described hereinand earth-boring tools utilizing the shank assembly 400 described hereinmay provide better steering and directional drilling in comparison toearth-boring tools having relatively longer shanks.

FIG. 6 is a perspective exploded view of a modular shank assembly 600according to one or more additional embodiments of the presentdisclosure. Similar the shank assembly 400 described above in regard toFIGS. 4A, 4B, and 5, the shank assembly 600 may include a neck portion602, a shank portion 604, and an anchor tube 606. Furthermore, the shankassembly 600 may generally have the same orientation and configurationof the shank assembly 400 described above. However, the shank portion604 may be separate and distinct from the neck portion 602. For example,the shank assembly 600 may include one or more sealing rings disposedbetween an upper longitudinal end 652 of the shank portion 604 (i.e., alongitudinal end of the shank portion 604 opposite a crown) and the neckportion 602. Furthermore, the shank portion 604 may be removably securedto the neck portion 602 a secure press-fit using the one or more sealingrings. In additional embodiments, the shank portion 604 may be removablysecured to the neck portion 602 via one or more welds. In additionalembodiments, the shank portion 604 may be removably secured to the neckportion 602 through a threaded connection. In further embodiments, theshank portion 604 may be removably secured to the neck portion 602through one or more of an epoxy connection, a shape-memory retainer, oneor more fasteners (e.g., bolts), and/or a brazed connection.Additionally, the shank portion 604 may be removably secured to the neckportion 602 via any other conventional connection.

Referring to FIGS. 4A-6 together, the modular shank assemblies andassociated earth-boring tools of the present disclosure may provideincreased space for electronics and sensors downhole in comparison toconventional earth-boring tools while minimizing size increases of theearth-boring tools. Additionally, because the shank assemblies of thepresent disclosure are modular (e.g., made from multiple distinctparts), the shank assemblies may enable faster installation times ofelectronics and sensors within the shank assemblies. Furthermore, theshank assemblies may provide improved direct load transfer in comparisonto conventional shank assemblies.

Embodiments of the present disclosure further include the followingembodiments.

Embodiment 1: A shank assembly, comprising a neck portion; a shankportion extending from the neck portion and defining a cylindricalaperture extending longitudinally therethrough; one or more sealingrings disposed at an interface between the neck portion and the shankportion; an anchor tube secured to the neck portion and extendingthrough the shank portion, the anchor tube and the shank portiondefining an annular cavity therebetween; and an electronics moduledisposed within the annular cavity and comprising at least one of anaccelerometer, a magnetometer, and a temperature sensor.

Embodiment 2: The shank assembly of embodiment 1, wherein the shankportion is secured to the neck portion via a press-fit.

Embodiment 3: The shank assembly of embodiments 1 and 2, wherein theelectronics module comprises one or more sensors mounted directly to oneor more of an outer surface of the anchor tube and an inner surface ofthe shank portion.

Embodiment 4: The shank assembly of embodiment 3, wherein the one ormore sensors comprise a strain gauge.

Embodiment 5: The shank assembly of embodiments 1-3, wherein the neckportion comprises: a central bore extending through the neck portion; anend-cap at least partially disposed within the central bore of the neckportion and comprising: a first flange; and a second flange; and a bodyportion extending between the first flange and the second flange,wherein an annular chamber is defined between the body portion of theend-cap and an interior wall of the central bore of the shank.

Embodiment 6: The shank assembly of embodiment 5, further comprising atleast one additional electronics module disposed within the annularchamber of the neck portion.

Embodiment 7: The shank assembly of embodiments 5 and 6, wherein a ratioof a volume of the annular chamber and the annular cavity is within arange of about 1.25 and about 0.75.

Embodiment 8: The shank assembly of embodiments 5-7, wherein the anchortube and the end cap form a single integral unit.

Embodiment 9: An earth-boring tool, comprising: a shank assembly,comprising: a neck portion; a shank portion extending from the neckportion and defining a cylindrical aperture extending longitudinallytherethrough; an anchor tube secured to the neck portion and extendingthrough the shank portion, the anchor tube and the shank portiondefining an annular cavity therebetween; and an electronic moduledisposed within the annular cavity configured to measure one or more ofan annular pressure, a bore pressure, weight-on-bit, torque-on-bit, or atemperature; and a crown secured to the shank portion and the anchorportion, wherein the annular cavity extends into the crown in an axialdirection a distance that is between about 10% and about 80% of anoverall axial length of the crown.

Embodiment 10: The earth-boring tool of embodiment 9, wherein the neckportion of the shank assembly comprises: a central bore extendingthrough the neck portion; at least one end-cap at least partiallydisposed within the central bore of the shank and comprising: a firstflange; a second flange; and a body portion extending between the firstflange and the second flange, wherein an annular chamber is definedbetween the body portion of the end-cap and an interior wall of thecentral bore of the shank.

Embodiment 11: The earth-boring tool of embodiment 10, furthercomprising at least one additional electronics module disposed withinthe annular chamber of the neck portion.

Embodiment 12: The earth-boring tool of embodiments 10 and 11, wherein aratio of a volume of the annular chamber and the annular cavity iswithin a range of about 1.25 and about 0.75.

Embodiment 13: The earth-boring tool of embodiments 9-12, wherein theshank assembly further comprises at least one sensor integral with awall of the shank portion of the shank assembly and configured tomeasure weight-on-bit, torque-on-bit, bore pressure, or annularpressure.

Embodiment 14: The earth-boring tool of embodiments 9-13, wherein theshank portion and the neck portion form a single integral unit.

Embodiment 15: The earth-boring tool of embodiments 9-13, wherein theshank portion and the neck portion comprise separate and distinct parts.

Embodiment 16: The earth-boring tool of embodiments 9-15, wherein theanchor tube maintains an at least substantially uniform diameterthroughout a length of the anchor tube extending through the shankportion and into the crown.

Embodiment 17: A method of forming an earth-boring tool, the methodcomprising: disposing an anchor tube of a shank assembly through acylindrical aperture of a shank portion of the shank assembly andsecuring the anchor tube to a neck portion of the shank assembly;disposing an electronics module within an annular cavity defined betweenan inner surface of the shank portion and an outer surface the anchortube of the shank assembly; and disposing the shank portion and anchortube of the shank assembly at least partially within a crown of theearth-boring tool such that annular cavity extends into the crown in anaxial direction a distance that is between about 10% and about 80% of anoverall axial length of the crown.

Embodiment 18: The method of embodiment 17, further comprising securingthe anchor tube of the shank assembly to the crown of the earth-boringtool.

Embodiment 19: The method of embodiments 17 and 18, further comprisingsecuring the shank portion of the shank assembly to a neck portion ofthe shank assembly, the neck portion comprising: a central boreextending through the neck portion; and at least one end-cap at leastpartially disposed within the central bore of the shank and comprising:a first flange; a second flange; and a body portion extending betweenthe first flange and the second flange, wherein an annular chamber isdefined between the body portion of the end-cap and an interior wall ofthe central bore of the shank.

Embodiment 20: The method of embodiment 19, further comprising disposingat least one additional electronics module within the annular chamber ofthe neck portion.

The embodiments of the disclosure described above and illustrated in theaccompanying drawings do not limit the scope of the disclosure, which isencompassed by the scope of the appended claims and their legalequivalents. Any equivalent embodiments are within the scope of thisdisclosure. Indeed, various modifications of the disclosure, in additionto those shown and described herein, such as alternative usefulcombinations of the elements described, will become apparent to thoseskilled in the art from the description. Such modifications andembodiments also fall within the scope of the appended claims andequivalents.

What is claimed is:
 1. A shank assembly, comprising: a neck portion; ashank portion extending from the neck portion and defining a cylindricalaperture extending longitudinally therethrough; at least one sealingring disposed at an interface between the neck portion and the shankportion; an anchor tube secured to the neck portion and extendingthrough the shank portion, the anchor tube and the shank portiondefining an annular cavity therebetween; and an electronics moduledisposed within the annular cavity and comprising at least one of anaccelerometer, a magnetometer, and a temperature sensor.
 2. The shankassembly of claim 1, wherein the shank portion is secured to the neckportion via a press-fit.
 3. The shank assembly of claim 1, wherein theelectronics module comprises one or more sensors mounted directly to oneor more of an outer surface of the anchor tube and an inner surface ofthe shank portion.
 4. The shank assembly of claim 1, wherein a ratio ofa cross-sectional area of material defined by the shank portion and theanchor portion extending through a plane to which a longitudinal axis ofthe shank assembly is orthogonal and an overall cross-sectional areadefined by an outer diameter of the shank portion is within a range of0.50 and about 0.90.
 5. The shank assembly of claim 1, wherein the neckportion comprises: a central bore extending through the neck portion;and an end-cap at least partially disposed within the central bore ofthe neck portion and comprising: a first flange; and a second flange;and a body portion extending between the first flange and the secondflange, wherein an annular chamber is defined between the body portionof the end-cap and an interior wall of the central bore of the neckportion.
 6. The shank assembly of claim 5, further comprising at leastone additional electronics module disposed within the annular chamber ofthe neck portion.
 7. The shank assembly of claim 5, wherein a ratio of avolume of the annular chamber and the annular cavity is within a rangeof about 1.25 and about 0.75.
 8. The shank assembly of claim 5, whereinthe anchor tube and the end cap form a single integral unit.
 9. Anearth-boring tool, comprising: a shank assembly, comprising: a neckportion; a shank portion extending from the neck portion and defining acylindrical aperture extending longitudinally therethrough; an anchortube secured to the neck portion and extending through the shankportion, the anchor tube and the shank portion defining an annularcavity therebetween; and an electronics module disposed within theannular cavity configured to measure one or more of an annular pressure,a bore pressure, weight-on-bit, torque-on-bit, or a temperature; and acrown secured to the shank portion and the anchor portion, wherein theannular cavity extends into the crown in an axial direction a distancethat is between about 10% and about 80% of an overall axial length ofthe crown.
 10. The earth-boring tool of claim 9, wherein the neckportion of the shank assembly comprises: a central bore extendingthrough the neck portion; and at least one end-cap at least partiallydisposed within the central bore of the neck portion and comprising: afirst flange; a second flange; and a body portion extending between thefirst flange and the second flange, wherein an annular chamber isdefined between the body portion of the end-cap and an interior wall ofthe central bore of the shank.
 11. The earth-boring tool of claim 10,further comprising at least one additional electronics module disposedwithin the annular chamber of the neck portion.
 12. The earth-boringtool of claim 10, wherein a ratio of a volume of the annular chamber andthe annular cavity is within a range of about 1.25 and about 0.75. 13.The earth-boring tool of claim 9, wherein the shank assembly furthercomprises at least one sensor integral with a wall of the shank portionof the shank assembly and configured to measure weight-on-bit,torque-on-bit, bore pressure, or annular pressure.
 14. The earth-boringtool of claim 9, wherein the shank portion and the neck portion form asingle integral unit.
 15. The earth-boring tool of claim 9, wherein theshank portion and the neck portion comprise separate and distinct parts.16. The earth-boring tool of claim 9, wherein the anchor tube maintainsan at least substantially uniform diameter throughout a length of theanchor tube extending through the shank portion and into the crown. 17.A method of forming an earth-boring tool, the method comprising:disposing an anchor tube of a shank assembly through a cylindricalaperture of a shank portion of the shank assembly and securing theanchor tube to a neck portion of the shank assembly; disposing anelectronics module within an annular cavity defined between an innersurface of the shank portion and an outer surface the anchor tube of theshank assembly; and disposing the shank portion and anchor tube of theshank assembly at least partially within a crown of the earth-boringtool such that annular cavity extends into the crown in an axialdirection a distance that is between about 10% and about 80% of anoverall axial length of the crown.
 18. The method of claim 17, furthercomprising securing the anchor tube of the shank assembly to the crownof the earth-boring tool.
 19. The method of claim 17, further comprisingsecuring the shank portion of the shank assembly to a neck portion ofthe shank assembly, the neck portion comprising: a central boreextending through the neck portion; and at least one end-cap at leastpartially disposed within the central bore of the neck portion andcomprising: a first flange; a second flange; and a body portionextending between the first flange and the second flange, wherein anannular chamber is defined between the body portion of the end-cap andan interior wall of the central bore of the shank.
 20. The method ofclaim 19, further comprising disposing at least one additionalelectronics module within the annular chamber of the neck portion.